Bag folding system

ABSTRACT

An automated system is disclosed for folding vehicle air bags so that a small folded bag profile in a desirable bag deployment pattern results. A machine having a holding fixture for receiving the retainer of an air bag assembly, and a plurality of upright members. A flattened bag with pleated sides is supported above the upright members, and sequentially inserted between the upright members forming undulating folds. The upright members are removed while retaining the undulating folds. The folds are then compressed, sharpening the folds and forming a compact package. The machine also includes an inserter assembly which inserts the folded bag into the retainer.

This application is a Continuation-in-Part of prior application Ser. No.08/044,820, filed 7 Apr. 1993, now U.S. Pat. No. 5,375,393.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the folding of flexible, multilayer,sheet-like articles, such as bags.

More particularly, the present invention relates to folding vehicularair bags.

In a further and more specific aspect, the present invention concerns amethod and apparatus for automated folding of vehicular air bags.

2. The Prior Art

Vehicular air bags are among the latest safety enhancements forautomobiles and other vehicles. Their use in vehicles is increasingdramatically. Generally, such air bags are located within a steeringwheel or column, dashboard, control panel, or other out-of-the-waylocation which is near a vehicle's occupant. Sensors located in thevehicle detect when a crash is occurring and activate the air bag(s).When activated, the air bags rapidly inflate between the vehicle'soccupant and a potentially injurious or deadly surface, such as asteering wheel. As the crash progresses, the force of the crash may hurlthe occupant toward the injurious or deadly surface, but the occupantfirst encounters the air bag, which prevents or otherwise lessens injuryto the occupant.

In order for the air bag to be effective, it must be stored in anout-of-the-way location until needed. Moreover, it must be stored insuch a manner that it can be rapidly activated to do its job. Due to thecontinual down-sizing of vehicles, the out-of-the-way locations whereair bags are typically located are usually rather small. Thus, an airbag must be folded into a small package so that it fits into a smalllocation. But, the technique used to fold the air bag affects itsdeployment when activated. To minimize the possibility of harm to avehicle occupant, the air bag preferably deploys evenly in a spreadingout (side-to-side) manner rather than shooting first toward one sidethen the other or shooting straight out then filling in fromside-to-side.

The conventional process for folding vehicular air bags relies almostexclusively on manual labor. This conventional process is plagued withproblems. For example, approximately 12 minutes are required to fold anair bag using manual labor. With the large number of air bags now beingused in vehicles, a tremendous amount of labor and expense is requiredto fold air bags. Moreover, the folding of air bags requires a largenumber of highly repetitive manual motions. Such repetitive motions arepotentially hazardous to the health of the manual laborers. In addition,such repetitive motions lead to boredom, which in turn leads to a poorperformance of the job.

Another problem relates to the consistency with which air bags arefolded using the conventional process. While some bags get foldedacceptably, others tend to be folded using a less-than-optimal foldingpattern or in a manner which results in an overly large package. Thislack of consistency results in a considerable amount of rework, which isexpensive, and inconsistent bag deployment patterns, which may poseunnecessary dangers to vehicle occupants.

Recent innovations have been developed in an attempt to automate thefolding of air bags. These innovations have only been partiallyeffective, however, since only a portion of the bag folding process isautomated. Generally, the bag folding process can be divided into twomain sequences, a horizontal fold sequence and a vertical fold sequence.The horizontal fold sequence forms pleated folds in the sides of the bagwhich flattens the bag and reduces it to the desired width. The verticalfold sequence folds the flattened bag into the small compact packagenecessary for installation on a vehicle.

A bag folding system has been developed, which is partially automated,automatically completing the first or horizontal fold sequence of theprocess. Air bags characteristically have top and bottom sections. Thebag folding system clamps the top and bottom sections together. Thisclamping action occurs near an edge portion of the bag and substantiallyrestricts inflation of the edge portion but leaves a central portion ofthe bag unclamped. After clamping, the central portion is inflated sothat the top section of the air bag separates from the bottom section.When the top and bottom sections have been separated, the clamped edgeportion is inserted into the central portion between the top and bottomsections. This system employs horizontal folds, resulting in a flattenedair bag having pleated sides. While very effective at completing thehorizontal fold sequence, the vertical fold sequence is accomplishedmanually.

Many air bags are folded to include a bubble fold. This is an extra foldin the air bag which inflates first, and aids in deploying the air bagevenly. At the present time bubble folds are formed manually, requiringan individual to perform numerous repetitions which may result infolding errors, and be potentially hazardous to the health of the manuallaborers.

It would be highly advantageous, therefore, to remedy the foregoing andother deficiencies inherent in the prior art.

Accordingly, it is an object of the present invention to provideimprovements in folding air bags.

Another object of the present invention is to provide an improved airbag folding system.

And another object of the present invention is to provide an automatedsystem for folding air bags.

Still another object of the present invention is to provide a system forquickly and efficiently folding air bags.

Yet another object of the present invention is to provide a system foruniformly folding air bags.

Yet still another object of the present invention is to provide a systemfor consistently folding air bags to achieve a desirable deploymentpattern.

A further object of the present invention is to provide a system forconsistently folding air bags to achieve a small folded-bag profile.

And a further object of the present invention is to provide a systemwhich automatically performs a vertical fold sequence.

Yet a further object of the present invention is to automatically insertan air bag into a retainer with an air bag bubble fold being formed.

SUMMARY OF THE INVENTION

Briefly, to achieve the desired objects of the instant invention inaccordance with a preferred embodiment thereof, provided is an apparatuswhich automatically folds an air bag having pleaded sides, and a bottomend coupled to a retainer. The apparatus includes a holding fixture forreceiving the retainer, and a platform for supporting and stretchingsaid bag out from the holding fixture. Also provided are means forforming vertical undulations also referred to as undulating folds alongthe length of the bag, and means for compressing the undulating folds.An inserter assembly is also provided for inserting the folded bag intothe retainer.

The above problems are solved, and the above objects are realized in amethod of folding a flattened air bag having pleated sides and an endcoupled to a retainer. The method includes forming undulating folds inthe flattened bag by inserting the bag sequentially between a series ofupright members. The upright members are then removed, and the foldscompressed. The folded bag is then inserted into the retainer.

An inserter assembly for packaging an air bag in preparation fordeployment is also disclosed, the inserter assembly including a firstblade movable between a rearward and a forward position, a second bladeindependently operable with respect to the first blade, and movablebetween a raised position and a lowered position, and a blade supportmovable between a raised and a lowered position, supporting the firstblade and the second blade in a substantially parallel relationship. Theinserter assembly further includes a first actuator coupling the firstblade to the blade support and a second actuator coupling the secondblade to the blade support.

Also contemplated is the inserter assembly including a fold panel havinga first edge pivotally supported adjacent a lower edge of the retainer,the fold panel movable from a lowered position substantiallyperpendicular to the retainer, to a raised position substantiallyparallel to and adjacent the retainer.

The above problems are solved, and the above objects are furtherrealized in a method of packaging an air bag in preparation fordeployment.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and further and more specific objects and advantages ofthe instant invention will become readily apparent to those skilled inthe art from the following detailed description of a preferredembodiment thereof, taken in conjunction with the drawings, in which:

FIG. 1 is a perspective view of a bag folding system, constructed inaccordance with the teachings of the instant invention, as it wouldappear prior to a first stage in the process for folding an air bag;

FIG. 2 is a perspective view of an inflated air bag;

FIG. 3 is a perspective view of an air bag after horizontal folding hasoccurred, flattening and forming side pleats in the air bag;

FIG. 4 is a perspective view of a portion of the bag folding system ofFIG. 1, with the air bag of FIG. 3 installed in preparation for verticalfolding;

FIG. 5A is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear in a first stage of the folding process;

FIG. 5B is a side view of a portion of the bag folding system of FIG. 1,as it would appear after the first stage of the folding process;

FIG. 6 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear beginning a second stage of the foldingprocess;

FIG. 7 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear continuing the second stage of the foldingprocess;

FIG. 8 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear continuing the second stage of the foldingprocess;

FIG. 9 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear finishing the second stage of the foldingprocess;

FIG. 10 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear after the second stage of the foldingprocess;

FIG. 11 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear after a third stage of the folding process;

FIG. 12 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear after a fourth stage of the folding process;

FIG. 13 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear after a fifth stage of the folding process;

FIG. 14A is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear in a sixth stage of the folding process;

FIG. 14B is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear after the sixth stage of the folding process;

FIG. 15A is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear beginning a seventh stage of the foldingprocess;

FIG. 15B is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear during the seventh stage of the foldingprocess;

FIG. 16 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear after the seventh stage of the foldingprocess;

FIG. 17 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear after an eighth stage of the folding process;

FIG. 18 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear after a ninth stage of the folding process;

FIG. 19 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear after a tenth stage of the folding process;

FIG. 20 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear after an eleventh stage of the foldingprocess;

FIG. 21 is a perspective view of a portion of the bag folding system ofFIG. 1, as it would appear after a twelfth stage of the folding process;

FIG. 22 is a perspective view of the folded air bag removed from aholding fixture;

FIG. 23 is a front view of a bag folding system, constructed inaccordance with the teachings of the instant invention, as it wouldappear prior to a first stage in the process for folding an air bag;

FIG. 24 is a perspective view of an inflated air bag;

FIG. 25 is a perspective view of an air bag after horizontal folding hasoccurred, flattening and forming side pleats in the air bag;

FIG. 26 is a perspective view of a portion of the bag folding system ofFIG. 23, with the air bag of FIG. 25 installed in preparation forvertical folding;

FIG. 27 is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear in a first stage of the folding process;

FIG. 28 is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear after the first stage of the foldingprocess;

FIG. 29 is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear after the completion of a second stage ofthe folding process;

FIG. 30 is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear after a third stage of the folding process;

FIG. 31 is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear beginning a fourth stage of the foldingprocess;

FIG. 32 is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear continuing the fourth stage of the foldingprocess;

FIG. 33 is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear continuing the fourth stage of the foldingprocess;

FIG. 34 is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear after the fourth stage of the foldingprocess;

FIG. 35 is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear after a fifth stage of the folding process;

FIG. 36 is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear after a sixth stage of the folding process;

FIG. 37A is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear in a seventh stage of the folding process;

FIG. 37B is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear after the seventh stage of the foldingprocess;

FIG. 38 is a perspective view of a portion of the bag folding system ofFIG. 23, as it would appear after an eighth stage of the foldingprocess;

FIG. 39 is a perspective view of the folded air bag removed from aholding fixture;

FIG. 40 is a partial perspective view illustrating a further embodimentof an inserter assembly positioned above a rolled air bag prior toinsertion of the rolled portion into a retainer;

FIG. 41A is a partial perspective view illustrating the inserterassembly positioned about the rolled portion at the beginning of aninsertion cycle;

FIG. 41B is an end view of the inserter assembly at the beginning of aninsertion cycle;

FIG. 42A is a partial perspective view illustrating removal of the clampassembly from engagement with the air bag;

FIG. 42B is an end view of the inserter assembly after removal of theclamping assembly;

FIG. 43 is a partial perspective view of the inserter assembly aftermovement of the rolled portion toward the retainer and movement of aninner blade to a raised position;

FIG. 44A is a partial perspective view illustrating insertion of therolled portion into the retainer and the formation of a bubble fold;

FIG. 44B is a side view of the insertion of the rolled portion into theretainer and the formation of a bubble fold;

FIG. 45A is a partial perspective view illustrating the folding of thebubble fold;

FIG. 45B is a side view of the folding of the bubble fold;

FIG. 46 is a partial perspective view illustrating insertion of thebubble fold into the retainer; and

FIG. 47 is a partial perspective view illustrating the step of securingthe air bag within the retainer.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to the drawings in which like reference characters indicatecorresponding elements throughout the several views, attention is firstdirected to FIG. 1 which illustrates a bag folding machine generallydesignated by the reference character 10. Bag folding machine 10consists of a planar base 12 supporting an upper accordion fold assembly13, a lower accordion fold assembly 14, an inserter assembly 15, aplatform 17 and a holding fixture 18. Holding fixture 18 is the focus ofthe various elements and is rigidly fixed to base 12. Lower accordionfold assembly 14 is carried by base 12 adjacent holding fixture 18.Platform 17 is carried by base 12 adjacent to and slightly elevatedabove lower accordion fold assembly 14 such that lower accordion foldassembly 14 is positioned between platform 17 and holding fixture 18.

Upper accordion fold assembly 13 includes a carriage 20 which carries ahold down assembly 23, a rotator assembly 24, and a blade assembly 25.Carriage 20 is movable between a rearward and forward position by anactuator (not shown) and guided by guides 22. In FIG. 1, carriage 20 isshown in the rearward position, moved back from lower accordion foldassembly 14. When in the forward position, carriage 20 positions holddown assembly 23 above platform 17, and positions rotator assembly 24and blade assembly 25 above lower accordion fold assembly 14.

Hold down assembly 23 includes a paddle 27 which is rotatable from anupright position, as shown in FIG. 1, to a lowered position, in whichpaddle 27 closely overlies platform 17 when carriage 20 is in theforward position. Paddle 27 has a pivot end 28 pivotally coupled tocarriage 20, and an opposing end 29 configured to closely overliecontact platform 17. An actuator 30 coupled between paddle 27 andcarriage 20 controls the rotation of paddle 27.

Blade assembly 25 includes, in this embodiment, seven upright blades 32.In viewing FIG. 1, each blade 32 is positioned parallel to one anotherand separately designated 32A-G respectively, beginning at the righthand side and moving to the left. Each of blades 32 are separatelymovable between a raised position, as shown in FIG. 1, and a loweredposition, in which each blade 32 interacts with lower accordion foldassembly 14 when carriage 20 is in the forward position. An actuator 33is coupled between carriage 20 and each blade 32 respectively forseparately moving blades 32 between the raised and lowered positions.

Rotator assembly 24 includes a substantially horizontal arms 34 and 35extending forwardly from a telescoping cross-piece 37. Cross-piece ispositioned rearward of and below blades 32 when they are in the raisedposition, with arms 34 and 35 extending forwardly to either side of andbelow the level of blades 32. Cross piece 37 is coupled to carriage 20by a rotatable spindle 38, not visible in FIG. 1, but can be seen withmomentary reference to FIG. 11. Telescoping cross-piece 37 moves arms 34and 35 between an expanded and a contracted position, actuated by anactuator 39.

Still referring to FIG. 1, lower accordion fold assembly 14 includes abase plate 40 and upright members 42 extending upwardly therefrom. Baseplate 40 is movable between a lowered position below the level ofplatform 17 as shown in FIG. 1, and a raised position where the upperends of upright members 42 are substantially even with platform 17. Baseplate 40 is moved between the lowered and the raised positions by anactuator 43. In this embodiment, six upright members are employed, andeach designated by the reference characters 42A-F, respectively, movingfrom right to left when viewing FIG. 1. A stripper plate 44 is carriedabove upright members 42, below the level of platform 17. Slots 45 areformed in stripper plate 44, configured to receive upright members 42when in the raised position.

Inserter assembly 15 includes a carriage 47 which carries a pair of pairof parallel vertical members 48 and 49 and a vertical end plate 50movable by an actuator 52, between a raised and a lowered position. Ahorizontal platform blade 53 extends outwardly from carriage 47,positioned below vertical walls 48 and 49, and movable by an actuator 55between a forward position and a rearward position. Carriage 47 ismovable between a rearward and forward position by an actuator (notshown) and guided by guides 54. In FIG. 1, carriage 47 is shown in therearward position, moved back from holding fixture 18. When in theforward position, carriage 47 positions vertical plates 48 and 49, andend plate 50 over holding fixture 18.

Turning now to FIG. 2, an air bag assembly generally designated 60 isillustrated in an inflated state. Air bag assembly 60 includes a bagretainer 62 secured to a sealed, flexible bag 63. Bag 63 includes abottom end 64 coupled to retainer 62, and opposing top end 65, a topportion 66, a bottom portion 67, and side portions 68.

As discussed in the background, folding air bag 63 can be divided intotwo general sequences. The first sequence involves flattening andnarrowing bag 63 by using horizontal folds to pleat side portions 68.The second sequence involves folding bag 63 into a compact package whichmay then be inserted into retainer 62. FIG. 3 illustrates bag assembly60 after the first sequence has been completed by manual folding asunderstood by those skilled in the art, or by an automated machine ashas been recently developed. Side portions 68 have been pleated withhorizontal folds, flattening bag 63 and reducing its width to match thewidth of retainer 62. In this configuration, top portion 66 overlaysbottom portion 67, with end 64 terminating in retainer 62.

Referring now to FIG. 4, bag assembly 63 is positioned within bagfolding machine 10. Retainer 62 is received within holding fixture 18,with flattened bag 63 extending over lower accordion fold assembly 14,and supported by platform 17.

Those skilled in the art will appreciate that control means is notshown, but is provided for operating and controlling the variousactuators necessary for the operation of machine 10. Those skilled inthe art will also appreciate that the precise programming instructionsand the nature of the control imparted through the control means andactuators has little bearing on the present invention, other than inaccomplishing the below discussed process. For example, while thepreferred embodiment of the present invention primarily uses pneumaticactuators, those skilled in the art may adapt hydraulic or solenoidactuators to impart the above discussed movements. Moreover, thoseskilled in the art will fully appreciate that limit or position switchesor sensors may be employed in a conventional fashion within machine 10to indicate to control means when desired positions are achieved throughsuch movements.

FIGS. 5A through 22 together present various states or stages throughwhich bag folding machine 10 and air bag assembly 60 progress in makingvertical folds in air bag 63. As discussed above, FIG. 4 illustrates aportion of machine 10 and bag assembly 60 prior to a first stage in thevertical folding process. Prior to the first stage, bag 63 is supportedby platform 17 except for the portion above lower accordion foldassembly 14. The first stage in the vertical fold process is illustratedin FIG. 5A. The first stage results from moving upper accordion foldassembly 13 in a direction indicated by arrowed line A, to its forwardposition, and moving lower accordion fold assembly 14 in a directionindicated by arrowed line B to its raised position with upright members42 extending through slots 45 of base plate 40. Included in the firststage is the movement of paddle 27 in a direction indicated by arrowedline C, from a raised position, to a lowered position contacting topportion 66 of bag 63. Arms 34 and 35 of rotator assembly 24 arepositioned under bag 63 parallel to and adjacent upright members 42A and42F. The completed first stage is illustrated in FIG. 5B, with a portionof bag 63 suspended between lower accordion fold assembly 14 and upperaccordion fold assembly 13.

FIGS. 6-10 illustrate the second stage of the vertical fold sequence. Inthe second stage, blades 32 are sequentially stroked downward forcingbag 63 between upright members 42, forming undulating folds along bag 63consisting of alternating folds 70 between upright members, and 72 overthe upper edges of upright members 42. Immediately preceding blades arekept in the lowered position to prevent removal of bag 63 from betweenupright members when a subsequent blade is stroked downward.

Referring specifically to FIG. 6, blade 32A is stroked downward in adirection indicated by arrowed line D, from its raised position to itslowered position. As blade 32A is stroked downward, bag 63 is forceddownward between upright member 42A and arm 34 forming a fold 70. Topend 65 of bag 63 is drawn inward in a direction indicated by arrowedline E as blade 32A forces bag 63 between upright member 42A and arm 34.After blade 32A is lowered, blade 32B is stroked downward from theraised position to the lowered position in the direction of arrowed lineF. Blade 32B forces bag 63 between upright members 42A and 42B and overthe end of upright member 42A forming fold 72 and a second fold 70.Blade 32A is kept in the lowered position, to act as a hold downpreventing removal of bag 63 from between upright members 42A and arm 34when blade 32B is lowered.

Referring now to FIG. 8, blade 32C is moved in a direction indicated byarrowed line G from a raised to a lowered position, forcing bag 63downward between upright members 42B and 42C, forming a third fold 70and second fold 72. At this point blade 32A is stroked upward in adirection indicated by arrowed line H. Blade 32B is retained in thelowered position. This process is continued until each of blades 32 isstroked from the raised to the lowered position, forcing bag 63 betweeneach of upright members 42. FIG. 9 illustrates blade 32G being strokeddownward in a direction indicated by arrowed line I forcing bag 63between upright member 42F and arm 35. At this point, top end 65 of bag63 moves off platform 17 in a direction indicated by arrowed line J.

Referring now to FIG. 10, blades 32 have all been moved upward to theraised position, with bag 63 forced between each of the upright members42 forming a plurality of folds 70 and 72.

FIG. 11 illustrates the third stage of the vertical fold sequence,immediately following the second stage. Blade assembly 25 is notillustrated in order that an unobstructed view of bag 63 is provided.Stage three consists of base plate 40 and upright member 42 beingstroked downward in a direction indicated by arrowed line K removingupright members 42 from slots 45 of stripper plate 44 without disturbingfolds 70 and 72 of bag 63. Vertical folds 70 and 72 are now maintainedby arms 34 and 35 of rotator assembly 24.

Stage four is illustrated in FIG. 12 and immediately follows stagethree. Stage four consists of moving arm 35 in a direction indicated byarrowed line L, from the expanded position to the contracted position.This stage compacts folds 70 and 72, and securely retains bag 63 betweenarms 34 and 35.

The fifth stage in the vertical fold sequence is illustrated in FIG. 13and immediately follows the fourth stage. During the fifth stage,platform blade 53 is moved in a direction indicated by arrowed line Mfrom a rearward position to the forward position closely overlyingholding fixture 18.

In viewing FIGS. 14A and B, the sixth stage consists of rotating spindle38 in a clockwise direction, indicated by curved arrow N, therebyrotating arms 34 and 35 and bag 63 contained therebetween in a directionindicated by arcuate arrow O. FIG. 14B illustrates rotator assembly 24after a complete 360 degree revolution. The revolution is completed witharms 34 and 35 positioning bag 63 above platform blade 53.

A seventh stage of the vertical fold sequence is illustrated in FIGS.15A and 15B, and consists of placing a compression plate 69 above bag 63between arms 34 and 35. Compression plate 69 has dimensionscorresponding to the dimensions of retainer 62. Referring now to FIG.15B, vertical members 48 and 49 and end plate 50 are stroked downward ina direction indicated by arrowed line P.

The seventh stage is completed by the removal of arms 34 and 35 asillustrated in FIG. 16. Arms 34 and 35 are moved in a directionindicated by arrowed line Q permitting vertical members 48 and 49 to bemoved in the direction of arrowed lines R and S respectively. This stepmay be accomplished in a wide variety of manners, but is illustrated asbeing biased inward by coil springs 73 and 74.

An eighth stage of the vertical fold sequence is illustrated in FIG. 17.Bag 63 is supported above retainer 62 by platform bag 53, and verticalmembers 48 and 49 are compressed inward along arrowed line R and Stightly compacting folds 70 and 72 of bag 63. This may be accomplishedby the use of any compressive force, but is preferably accomplished byusing actuators 77 and 78 as shown in FIG. 17.

A ninth stage of the vertical fold sequence is illustrated in FIG. 18,and consists of stroking platform blade 53 in a rearward directionindicated by arrowed line T. Bag 63 is now supported above retainer 62by vertical members 48 and 49. A tenth stage is illustrated in FIG. 19and includes lowering vertical members 48 and 49 in a directionindicated by arrowed lines U, and lowering compression plate 69 in adirection indicated by arrowed line V. The combination of verticalmembers 48 and 49 and compression plate 69 forces bag 63 into retainer62. Vertical members 48 and 49 and end plate 50 are then stroked upwardin a direction indicated by arrowed lines W as illustrated in FIG. 20.Compression plate 69 is then removed leaving a compactly folded bag 63housed in retainer 62. Retainer 62 is then removed from holding fixture18 for installation in a vehicle.

Turning now to FIG. 23, another embodiment of a bag folding machinegenerally designated 110 is illustrated. Bag folding machine 110consists of a planar base 112 supporting an upper accordion foldassembly 113, a lower accordion fold assembly 114, an inserter assembly115, spaced apart, generally horizontal platforms 117 and a holdingfixture 118. Holding fixture 118 is the focus of the various elements,and is rigidly fixed to base 112. Lower accordion fold assembly 114 isdivided into two spaced apart components, which for purposes ofreference are designated right lower accordion fold assembly 114Acarried by base 112 to the right of and adjacent to holding fixture 118,left lower accordion fold assembly and 114B carried by base 112 to theleft of and adjacent to holding fixture 118. Platform 117 is alsoseparated into two sections, which for purposes of reference aredesignated platform 117A carried slightly elevated with respect to andto the right of assembly 114A, and platform 117B carried slightlyelevated with respect to and to the left of component 114B.

Upper accordion fold assembly 113 includes a carriage 120 which carriesa hold down assembly 123, and a blade assembly 125. Hold down assembly123 is not illustrated in FIG. 23, but can be seen with additionalreference to FIG. 29. For purposes of reference, holding down assembly123 is divided into a left portion 123A mounted to the left side ofcarriage 120 and a right portion 123B mounted to the right side ofcarriage 120. Portions 123A and 123B each include a paddle 127A and 127Brespectively which is rotatable from an upright position, to a loweredposition, in which paddles 27A and 27B closely overlie platforms 117Aand 117B.

Blade assembly 125, for purposes of reference, is separated into bladeassemblies 125A configured to interact with lower component 114A, andblade assembly 125B configured to interact with lower component 114B.Carriage 120 is movable between a rearward and a forward position by anactuator, not shown. In the forward position, carriage 120 positionshold down assembly 123A and 123B above platform 117A and 117Brespectively, and blade assembly 125A and 125B above lower accordionassemblies 114A and 114B respectively.

Blade assembly 125A includes, in this embodiment, three upright blades132. In viewing FIG. 23, each blade 132 is positioned parallel to oneanother and separately designated 132A-C respectively, beginning at theleft hand side and moving to the right. Each of blades 132 areseparately movable between a raised position, as shown in FIG. 123, anda lowered position, in which each blade 132 interacts with loweraccordion fold assembly 114A when carriage 120 is in the forwardposition. An actuator 133 is coupled between carriage 120 and each blade132 respectively for separately moving blades 132 between the raised andlowered positions. Blade assembly 125B includes, in this embodiment,five upright blades 134, each designated 134A-E respectively beginningat the right hand side and moving to the left when viewing FIG. 23. Eachof blades 134 is separately movable between a raised position, as shownin FIG. 23, and a lowered position, in which each blade 134 interactswith lower accordion fold assembly 114B when carriage 120 is in theforward position. An actuator 135 is coupled between carriage 120 andeach blade 134 respectively for separately moving blades 134 between theraised and lowered positions.

Inserter assembly 115 is mounted to carriage 120 intermediate bladeassemblies 125A and 125B, positioned above holding fixture 118. Inserterassembly 115 consists of a compression plate 136 movable between araised position and a lowered position closely overlying holding fixture118, by an actuator 137. A center blade 138 extends down centrallythrough compression plate 136, and is movable between a raised position,and a lowered position by an actuator 139. Inserter assembly 115 furtherincludes a compression member 148 mounted to the right of loweraccordion fold assembly 114A and a compression member 149 mounted to theleft of lower accordion fold assembly 114B. Compression members 148 and149 are movable inward toward holding fixture 118 by actuators 150 and152 respectively.

Still referring to FIG. 23, lower accordion fold assembly 114A includesa base plate 140A and upright members 142 extending upwardly therefrom.Base plate 140A is movable between a lowered position below the level ofplatform 117A and a raised position, as shown in FIG. 23, where theupper ends of upright members 142 are substantially even with platform117A. Base plate 140A is moved between the lowered and the raisedpositions by an actuator 143A. In this embodiment, four upright membersare employed, and designated by the reference characters 142A-Dbeginning from the left hand side and moving towards the right whenviewing FIG. 23. A stripper plate 144A is carried above uprights 142,below the level of platform 117A. Slots 145A are formed in stripperplate 144A, configured to receive upright members 142 when in the raisedposition.

Lower accordion fold assembly 114B includes a base plate 140B andupright members 146 extending upwardly therefrom. Base plate 140B ismovable between a lowered position below the level of platform 117B anda raised position where the upper ends of upright members 146 aresubstantially even with platform 117B. Base plate 140B is moved betweenthe lowered and the raised positions by an actuator 143B. In thisembodiment, six upright members are employed, and designated by thereference characters 146A-F, beginning from the right hand side andmoving towards the left when viewing FIG. 23. A stripper plate 144B iscarried above uprights 146, below the level of platform 117B. Slots 145Bare formed in stripper 144B, configured to receive uprights 146 when inthe raised position.

Turning now to FIG. 24, an air bag assembly generally designated 160 isillustrated in an inflated state. Air bag assembly 160 includes a bagretainer 162 secured to a sealed, flexible bag 163. Bag 163 includes abottom end 164 coupled to retainer 162, an opposing top section 165, andside portions 168.

As discussed in the background and earlier in the description of thefirst embodiment, folding air bag 163 can be divided into two sequences.The first sequence involves flattening and narrowing bag 163 by usinghorizontal folds to pleat side portions 168. The second sequenceinvolves folding bag 163 into a compact package which may then beinserted into retainer 162. FIG. 25 illustrates bag assembly 160 afterthe first sequence has been completed by manual folding as understood bythose skilled in the art or by an automated machine as has been recentlydeveloped. Side portions 168 have been pleated with horizontal folds,flattening bag 163 such that top portion 165 overlies bottom end 164,and reducing its width to match the width of retainer 162. Thisconfiguration, as viewed horizontally, includes a right end 169A and aleft end 169B.

Those skilled in the art will appreciate that control means is providedfor operating and controlling the various actuators necessary for theoperation of machine 110. Those skilled in the art will also appreciatethat precise programming instructions and the nature of the controlimparted through the control means and actuators has little bearing onthe present invention, other than in accomplishing the below discussedprocess. For example, while the preferred embodiment of the presentinvention primarily used pneumatic actuators, those skilled in the artmay adapt hydraulic or solenoid to impart the above discussed movements.Moreover, those skilled in the art will fully appreciate that limit orposition switches or sensors may be employed in a conventional fashionwithin machine 110 to indicate to control means when desired positionsare achieved through such movements.

Referring now to FIG. 26, bag assembly 163 is positioned within bagfolding machine 110. Retainer 162 is received within holding fixture118, with right end 169A of flattened bag 163 extending over loweraccordion fold assembly 114A, and supported by platform 117A, and leftend 169B of flattened bag 163 extending over lower accordion foldassembly 114B, and supported by platform 117B.

FIGS. 27-39 together present various states or stages through which bagfolding machine 110 and air bag assembly 160 progress in making verticalfolds in air bag 163. As discussed above, FIG. 26 illustrates a portionof machine 110 and bag assembly 160 prior to a first stage in thevertical folding process. Prior to the first stage, bag 163 is supportedby platform 117A and 117B except for the central portion above loweraccordion fold assemblies 114A and 114B. The first stage in the verticalfold process is illustrated in FIG. 27, and consists of stroking loweraccordion fold assemblies 114A and 114B upward in a direction indicatedby arrowed lines AA. This brings the upper edges of upright members 142and 146 substantially even with platforms 117A and 117B. As illustratedin FIG. 28, the first stage is completed by moving upper accordion foldassembly 113 forward in a direction indicated by arrowed lines BB suchthat upper accordion fold assembly 113A closely overlies right end 169Aof air bag 163, positioned above lower accordion fold assembly 114A,upper accordion fold assembly 113B closely overlies left end 169B of airbag 163, positioned above lower accordion fold assembly 114B, andinserter assembly 115 is positioned above holding fixture 118.

A second stage of the vertical fold sequence is illustrated in FIG. 29wherein paddles 127A and 127B are moved in a direction indicated byarrowed line CC from a raised position to a lowered position contactingright end 169A and left end 169B of bag 163 respectively.

A third stage of the vertical folding sequence is illustrated in FIG. 30and consists of moving center blade 138 of inserter assembly 115 in adirection indicated by arrowed line DD, from the raised position to thelowered position, inserting top portion 165 of air bag 163 into retainer162. Center blade 138 is kept in the lowered position to act as a holddown preventing subsequent unintentional removal of top portion 165 fromretainer 162.

A fourth stage of the vertical folding sequence is illustrated in FIGS.31-34 in which undulations, also referred to as undulating folds areformed along bag 63. Blade assembly 125A is actuated first, in thispreferred embodiment, with blades 132 being stroked from the raisedposition to the lowered position in sequence beginning with blade 132Aas shown in FIG. 31. Blade 132A forces air bag 163 downward betweenupright members 142A and 142B forming a fold 170 adjacent stripper panel144A. As air bag 163 is inserted between upright members 142, right end169A moves inward in a direction indicated by arrowed line EE. FIG. 32illustrates the sequential movement of first blade 132B, then 132Cstroked downward forcing bag 163 downward between upright members 142,forming additional folds 172 over the upper edges of upright members142.

After the formation of folds 170 and 172 in right end 169A, each ofblades 134 of blade assembly 125B, is stroked downward in sequencebeginning with blade 134A. As each blade is stroked downward insequence, folds 170 are formed between upright members 146 and folds 172are formed over the ends of upright members 146. Referring to FIG. 33,the immediately preceding blade 134 remains in a downward strokedposition to act as a hold down for air bag 163 during the subsequentdownward stroke of the next blade 134 in sequence.

The completion of stage four is illustrated in FIG. 34. The completionof stage four consists of moving the final blades acting as hold downblades, which in this embodiment are blades 132A and 134E, in an upwarddirection designated by arrowed line FF. Bag 163 has now been forcedbetween each of the upright members 142 and 146, forming a plurality offolds 70 and 72.

A fifth stage of the vertical fold sequence is illustrated in FIG. 35and immediately follows the fourth stage. Upper accordion fold assembly113 is not visible, in order that an unobstructed view of bag 163 isprovided. Stage five consists of base plate 140A with upright members142 and base plate 140B with upright members 146 being stroked downwardin a direction indicated by arrowed lines GG, removing upright members142 and 146 from slots 145A and slots 145B of stripper plate 144A and144B respectively, without disturbing folds 170 and 172 of bag 163.Vertical folds 170 and 172 are now maintained upon stripper plates 144Aand 144B by compression members 148 and 149 respectively. A sixth stageof the folding sequence immediately following the fifth stage, isillustrated in FIG. 36. Compression members 148 and 149 are moved inwardcompressing folds 170 and 172 of bag 163. Bag 163 is compressed aboutcenter blade 138, to a size receivable within retainer 162.

A seventh stage immediately following the sixth stage is illustrated inFIGS. 37A and 37B. In the seventh stage, compression plate 136 is movedin a downward direction indicated by arrowed line HH. Compression plate136 contacts bag 163 and forces it from between compression members 148and 149 downward into retainer 162 as illustrated in 37B.

An eighth stage of the folding sequence immediately following theseventh stage is illustrated in FIG. 38. In the eighth stage, centerblade 138 is moved upward in a direction indicated by arrowed line II,compression plate 136 is moved upward in a direction indicated byarrowed line JJ, upper accordion fold assembly 113 is moved rearwardremoving the assembly from above holding fixture 118 and compressionmembers 148 and 149 are moved in a direction indicated by arrowed linesKK and LL respectively.

The final stage in the folding sequence is illustrated in 39, andconsists in removing retainer 162 containing folded air bag 163 fromholding fixture 118.

A further embodiment of an inserter assembly generally designated 200and a cycle of inserting an air bag 202 into a retainer 203 isillustrated in FIGS. 40-47. Inserter assembly 200 automatically packagesair bag 202 in preparation for deployment, by inserting air bag 202 intoretainer 203 in such a manner as to form a fold therein, often referredto as a bubble or bubble fold. A bubble fold is known in the art, andemployed to aid in the uniform inflation of air bag 202. Air bag 202 iscoupled to retainer 203 which is held securely in a holding fixture 204.One skilled in the art will understand that air bag 202 may be compactedin substantially any manner such as being folded by bag folding machine10 as illustrated in FIGS. 1-14, with insertion of the folded air bagaccomplished by inserter assembly 200 replacing inserter assembly 15. Torepresent the diverse uses of inserter assembly 200, however, air bag202 is illustrated as having been rolled in a conventional manner, wellknown to those skilled in the art. A clamp assembly 205 consisting ofopposing clamp members 207 and 208 clamp an end 209 of air bag 202.Clamp assembly 205 is rotated in the direction indicated by arcuatearrowed line MM, rolling air bag 202 around clamp members 207 and 208 toform a rolled portion 210. Air bag 202 is rolled to a point proximateretainer 203, with rolled portion 210 coupled to retainer 203 by acoupling portion 211, as shown in FIG. 40. Clamp assembly 205 and therolling procedure are not shown in detail as they are well known in theart and included for purposes of reference and orientation.

Inserter assembly 200 is carried on a movable carriage (not shown) whichmoves inserter assembly 200 inward and outward, between a forwardposition and rearward position. The terms inward and outward as usedhere, refer to a direction toward holding fixture 204 and away fromholding fixture 204, respectively. Inserter assembly 200 consists of ablade support 212 movable between a raised position and a loweredposition by an actuator 213. Blade support 212 has an inner end 214 andan outer end 215. Inner end 214 supports an inner blade 217 and outerend 215 supports an outer blade 218 substantially parallel to and spacedfrom inner blade 217. A gate panel 223 is coupled to an edge of innerblade 217 and spans the distance between inner blade 217 and outer blade218 at one end. A slot 224 is formed through the lower end of gate panel223, the purpose of which will be described below. Inner blade 217 andouter blade 218 are independently movable by actuators 219 and 220respectively. Actuator 219 couples inner blade 217 to inner end 214,movable between a raised position and a lowered position with respect toblade support 212. Actuator 220 couples outer blade 218 to a drop member222 extending downward from outer end 215. Drop member 222 positionsouter blade 218 at substantially the same level as inner blade 217 wheninner blade 217 is in the lowered position. Actuator 220 moves outerblade 218 in an inward direction and in an outward direction, between arearward position and a forward position with respect to blade support212.

A first stage of the insertion cycle, consisting of positioning inserterassembly 200, is illustrated in FIG. 40. Actuator 213 is operated,moving blade support 212 downward to the lowered position, in adirection indicated by arrowed lines NN. Inner blade 217 is in thelowered position between rolled portion 210 and holding fixture 204, andouter blade 218 is in the rearward position. As can be seen withreference to FIGS. 41A and 41B, inner blade 217 and outer blade 218 arepositioned above the lowest edge of holding fixture 204 and retainer203. Gate portion 223 is received about clamp assembly 205, with clampmembers 207 and 208 extending through slot 224.

A second stage of the insertion cycle, consisting of removing clampassembly 205, is illustrated in FIGS. 41A-42B. Referring first to FIGS.41A and 41B, inner blade 217 and outer blade 218 are positioned onopposing sides of rolled portion 210 after the first stage. Outer blade218 is moved inward, towards inner blade 217 in a direction indicated byarrowed line OO by actuator 220, compressing rolled portion 210 againstinner blade 217. Gate panel 223 is illustrated broken away from innerblade 217 to provide a clear view of slot 224.

FIGS. 42A and 42B illustrate the removal of clamp assembly 205 fromrolled portion 210. Clamping members 207 and 208 are extracted fromrolled portion 210 in a direction indicated by arrowed line PP. Gatepanel 223 permits extraction of clamping members 207 and 208 throughslot 224, while preventing skewing of air bag 202. Slot 224 is sized topermit free movement of clamp members 207 and 208 while preventing airbag 202 from being drawn along therewith and distorting rolled portion210.

A third stage of the insertion cycle, consisting of forming a bubblefold, is illustrated beginning in FIGS. 42A and 42B and continuing inFIGS. 43-44B. After removal of clamp assembly 205, inserter assembly 200is moved inward in a direction indicated by arrowed lines QQ, towardsretainer holding fixture 204, to the forward position. In the forwardposition, inner blade 217 resides adjacent holding fixture 204 as can beseen with additional reference to FIG. 43.

As inserter assembly 200 is moved inward to the forward position, a foldof material is passed over and left behind. In the lowered position, asdescribed previously, inner blade 217 and outer blade 218 are positionedabove the lowest portion of retainer 203, resulting in rolled portion210 being moved over coupling portion 211 of air bag 202. The foldformed in coupling portion 211 of air bag 202 is the beginnings of abubble fold 225 which extends outward from retainer 203 and passesunderneath rolled portion 210.

After inserter assembly 200 is moved inward to the forward position,actuator 219 is operated to move inner blade 217 in an upward directionas indicated by arrowed line RR, to the raised position. As actuator 219raises inner blade 217, outer blade 218 is moved inward by actuator 220.As inner blade 217 clears an upper edge of holding fixture 204 andretainer 203, outer blade 218 pushes rolled portion 210 of air bag 202into retainer 203 as can be seen in FIGS. 44A and 44B. As rolled portion210 is pushed, it moves over coupling portion 211, enlarging the foldleft behind and thereby forming bubble fold 225. Bubble fold 225 extendsoutward from retainer 203 substantially the same distance as the widthof retainer 203. A retaining cover 227 can be seen extending fromretainer 203 under bubble fold 225. Retaining cover 227 has an outeredge 226 which is affixable to retainer 203 for purposes which will bedescribed below.

Inserter assembly 200 further includes a fold plate 228 having an outeredge 229 and a pivot edge 230. Pivot edge 230 is pivotally coupled to asupport (not shown), proximate the lower edge of holding fixture 204. Anactuator 232 pivots fold plate 228 about pivot edge 230 in a directionindicated by arcuate arrowed line SS, from a lowered position to araised position. In the raised position outer edge 229 of fold plate 228is positioned adjacent the upper edge of holding fixture 204. As withthe previous actuators, actuator 232 is preferably a double actingcylinder, and has an end 233 pivotally coupled to fold plate 228.

A fourth stage of the insertion cycle, consisting of inserting bubblefold 225 into retainer 203, is illustrated in FIGS. 45A-46. As can beseen in FIGS. 45A and 45B, actuator 232 is operated, pivoting fold plate228 to the raised position. Fold plate 228 carries bubble fold 225 andretaining cover 227 upward as it pivots about pivot edge 230. Outer edge229 is angled upward to aid in guiding bubble fold 225 into retainer203. As fold plate 228 folds bubble fold 225 upward prior to insertioninto retainer 203, outer plate 218 is moved upward in a directionindicated by arrowed line TT. The removal of outer plate 218 permitsfold plate 228 to force bubble fold 225 into retainer 203. When foldplate 228 reaches the fully raised position as shown in FIG. 46, bubblefold 225 is fully inserted into retainer 203.

The final stage of the insertion cycle is affixing outer edge 226 ofretaining cover 227 to retainer 203. At this stage, fold plate 228 isalso rotated back to the lowered position to allow access to retainingcover 227. One skilled in the art will understand that numerous meansare available for affixing outer edge 226 to retainer 203, including butnot limited to an adhesive strip 234. Retaining cover 227 holds air bag202 within retainer 203 until inflation is required, and preferablyconsists of a rupturable or frangible material such as is manufacturedby DuPont under the trade name TYVEK.

Various changes and modifications to the embodiments herein chosen forpurposes of illustration will readily occur to those skilled in the art.To the extent that such modifications and variations do not depart fromthe spirit of the invention, they are intended to be included within thescope thereof which is assessed only by a fair interpretation of thefollowing claims.

Having fully described the invention in such clear and concise terms asto enable those skilled in the art to understand and practice the same,the invention claimed is:
 1. A method of automatically packaging an airbag for deployment, said method comprising the steps of:providing saidair bag including a first end coupled to a retainer, a second end in acompacted state, and a coupling portion coupling said second end to saidfirst end; forming a bubble fold in said coupling portion; insertingsaid second end into said retainer; inserting said bubble fold into saidretainer; and securing said air bag within said retainer.
 2. A method asclaimed in claim 1 wherein the step of forming said bubble fold includesthe step of moving said second end over said coupling portion towardsaid retainer.
 3. A method as claimed in claim 2 wherein the step ofmoving said second end over said coupling portion includes the stepsof:providing a first blade movable between a rearward and a forwardposition; providing a second blade independently operable with respectto said first blade, and movable between a raised position and a loweredposition; providing a movable blade support, supporting said first bladeand said second blade in a substantially parallel relationship;positioning said first blade and said second blade on opposing sides ofsaid second end of said air bag; and moving said blade support towardssaid retainer.
 4. A method as claimed in claim 3 wherein the step ofinserting said second end includes:raising said second blade; and movingsaid first blade to said forward position.
 5. A method as claimed inclaim 4 wherein the step of inserting said bubble fold includes thesteps of:providing a fold panel pivotally movable from a loweredposition to a raised position; moving said fold panel to said raisedposition; and raising said first plate.
 6. A method as claimed in claim5 wherein the step of securing said air bag within said retainerincludes the steps of:providing a retaining cover coupled at a firstedge to said retainer and having an opposing second edge; covering saidair bag with said retaining cover; and affixing said second edge to saidretainer.
 7. An inserter assembly for packaging an air bag inpreparation for deployment, said inserter assembly comprising:a firstblade movable between a rearward and a forward position; a second bladeindependently operable with respect to said first blade, and movablebetween a raised position and a lowered position; and a blade supportmovable between a raised and a lowered position, supporting said firstblade and said second blade in a substantially parallel relationship. 8.An inserter assembly as claimed in claim 7 further including:a firstactuator coupling said first blade to said blade support; and a secondactuator coupling said second blade to said blade support.
 9. Aninserter assembly as claimed in claim 8 further including a fold panelhaving a first edge pivotally supported adjacent a lower edge of saidretainer, said fold panel movable from a lowered position substantiallyperpendicular to said retainer to a raised position substantiallyparallel to and adjacent said retainer.